Rahman, Faisal and Sugiono, ST., MT., PhD and Dr. Ir. Achmad As’ad Sonief, MT, and Ir. Oyong Novareza, ST., MT. PhD, (2022) Optimasi Gabungan Overall Equipment Effectiveness Dan Machine’s Reliability Untuk Meningkatkan Maintenance Performance Level. Doktor thesis, Universitas Brawijaya.
Abstract
Dampak terbesar dari kegagalan mesin adalah berhentinya operasional secara keseluruhan. Sehingga penting untuk menjaga keandalan mesin melalui pemeliharaan yang terencana dengan baik. Tujuan daripada pemeliharaan mesin dalam suatu industri adalah untuk memperbaiki atau memelihara mesin pada kondisi kerja yang baik dan dapat diterima. Selain hal tersebut, penilaian kinerja mesin dengan key performance indicator (KPI) juga sudah menjadi kebutuhan utama dalam dunia industri saat ini. Maintenance performance level (MPL) merupakan salah satu KPI untuk menilai efektifitas pemeliharaan mesin yang memiliki dua faktor utama yaitu overall equipment effectiveness-machine effectiveness (OEE-ME) dan machine reliability (MR). Banyak penelitian sudah dilakukan para peneliti sebelumnya terkait OEE-ME dan MR. Untuk memudahkan review maka dalam penelitian ini menggunakan bantuan software publish or perish dan Vos viewer untuk memetakan penelitian sebelumnya dengan data pencarian tren terbaru 2012-2021. Hasil pemetaan menunjukan adanya hubungan reliability dengan availability, performance, maintenance, OEE dan optimization. Kemudian dari reliability dan OEE menunjukan reliability assessment, reliability level, machine effectiveness dan optimization adalah bagian yang jarang diteliti. Oleh karena itu, hal ini dapat menimbulkan celah untuk dilakukan penelitian lebih lanjut. Selanjutnya penelitian ini melakukan review terhadap penelitian sebelumnya untuk menemukan celah penelitian dan keterbaruan. Hasil review yaitu penelitian ini berbeda dari penelitian sebelumnya, yang mana penelitian sebelumnya hanya mengukur dan menghitung nilai OEE. Meskipun ada juga penelitian sebelumnya yang mencoba meningkatkan nilai OEE, namun hasil peningkatan tersebut belum dapat memberikan hasil yang maksimal yaitu mencapai benchmark world-class dengan nilai minimum OEE 85%. Sedangkan penelitian lain terkait reliability hanya berfokus pada analisa keandalan mesin dengan hasil akhir rekomendasi perbaikan tanpa KPI yang dapat menunjukkan seberapa sukses perbaikan yang dilakukan. Hanya sedikit peneliti yang melakukan penelitian untuk meningkatkan nilai OEE melalui analisa reliability. Namun penelitian mereka hanya terfokus pada peningkatan nilai OEE, sedangkan penilaian keandalan mesin tidak dilakukan. Hanya Samat et al. (2012) yang melakukan perhitungan pada OEE-ME dan MR. Kemudian perhitungan OEE-ME dan MR dinilai dengan MPL. Tetapi penelitian yang dilakukan oleh Samat et al. (2012) hanya sebatas hanya sebatas melakukan perhitungan tanpa ada upaya peningkatan nilai OEE-ME, MR dan MPL. Pada penelitian disertasi ini, peneliti melakukan hal yang berbeda dari peneliti sebelum-sebelumnya yaitu dengan melakukan penelitian optimisasi gabungan OEE-ME dan MR yang pada akhirnya akan meningkatkan MPL pada unit mobile crane (lifting equipment) yang berada di Jetty di salah satu perusahaan Migas Indonesia yang belum pernah ditemukan pada penelitian sebelumnya. Mobile crane merupakan lifting equipment yang berfungsi untuk mengangkat dan menurunkan material secara vertikal dan memindahkannya secara horizontal. Mobile crane diaplikasikan secara luas dalam perakitan baja dan struktur beton bertulang, perbaikan dan penanganan material. Keuntungan mobile crane adalah mobilitas, kecepatan perjalanan dan pengaturan cepat di lokasi kerja. Mobile crane terbagi beberapa jenis yaitu articulating boom crane untuk area sempit dengan kapasitas angkat kecil. Sedangkan mobile crane dengan kapasitas sedang sampai besar seperti crawler crane umumnya digunakan di medan kasar dan berlumpur, rought terrain crane untuk medan kasar dan berat, all terrain crane dapat digunakan di segala kondisi medan kerja. Dalam peneltian ini menggunakan mobile crane jenis all terrain crane. Secara umum sistem mobile crane terbagi beberapa bagian utama yaitu main system, system, subsystem dan komponen utama. Main system terdiri dari lower structure dengan systemnya seperti powertrain, wheel, brake & steering system, carrier frame & suspension system, dan outrigger mechanism. Main system electric & safety equipment dengan systemnya seperti lamps & dashboard dan safety devices. Main system upper structure system terdiri dari swing mechanism, boom mechanism dan lifting device. Tentunya kegagalan fungsi dan sistem mobile crane akan menimbulkan kerugian yang cukup besar terhadap kegiatan operasional baik di darat (onshore) maupun di lepas pantai (offshore). Agar operasional bongkar muat material/logistik di Jetty dengan mobile crane yang dioperasikan secara terus-menerus dapat berjalan lancar maka diperlukan pemeliharaan yang baik. Saat ini, perusahaan menerapkan strategi pemeliharaan mobile crane dengan menggunakan metode preventive maintenance dan corrective maintenance.
English Abstract
The most significant impact of machine failure is the complete cessation of operations. So it is important to maintain the machine's reliability through well-planned maintenance. The purpose of machine maintenance in an industry is to repair or maintain machines in good and acceptable working conditions. In addition, machine performance evaluation using key performance indicators (KPI) has become a major requirement in today's industrial world. Maintenance performance level (MPL) is one of the KPIs to assess the effectiveness of machine maintenance which has two main factors, namely overall equipment effectiveness-machine effectiveness (OEE-ME) and machine reliability (MR). Many studies have been carried out by previous researchers regarding OEE-ME and MR. To facilitate a review, this research uses the help of publish or perish software and Vos viewer to map previous research with the latest 2012-2021 trend search data. The mapping results show that there is a relationship between reliability and availability, performance, maintenance, OEE and optimization. Then reliability and OEE show reliability assessment, reliability level, machine effectiveness, and optimization are parts that are rarely studied. Therefore, this can create gaps for further research. Furthermore, this study conducted a review of previous research to find research gaps and updates. The results of the review are that this study is different from previous studies, in which previous studies only measured and calculated OEE values. Although there have also been previous studies that have tried to increase the OEE value, the results of this increase have not been able to provide maximum results, namely achieving world-class benchmarks with a minimum OEE value of 85%. Meanwhile, other research related to reliability only focuses on analyzing machine reliability with the final result of recommendations for improvements without KPIs that can show how successful the improvements have been. Only a few researchers have conducted research to increase the value of OEE through reliability analysis. However, their research only focused on increasing the OEE value, while evaluating machine’s reliability was not carried out. Only Samat et al. (2012) performed calculations on OEE-ME and MR. Then the OEE-ME and MR calculations are assessed by MPL. But research conducted by Samat et al. (2012) was limited to doing calculations without any effort to increase the OEE-ME, MR and MPL values. In this dissertation research, the researcher is doing something different from previous researchers, namely by conducting a combined OEE-ME and MR optimization research which will ultimately increase the MPL on the mobile crane unit (lifting equipment) located at the Jetty of one of the Indonesian oil and gas companies, which had not been found in previous studies. A Mobile crane is a lifting equipment that functions to lift and lower material vertically and move it horizontally. Mobile cranes are widely applied in steel and reinforced concrete structure assembly, repair, and materials handling. The advantages of mobile cranes are mobility, traveling speed, and quick setup on the job site. Mobile cranes are divided into several types, namely articulating boom cranes for narrow areas with small lifting capacities. Whereas mobile cranes with medium to large capacities, such as crawler cranes, are generally used in rough and muddy terrain, rough terrain cranes for rough and heavy terrain, all terrain cranes can be used in all working field conditions. This research uses a mobile crane-type all-terrain crane. The mobile crane system is generally divided into several main parts, namely the main system, system, subsystem, and main components. The main system consists of a lower structure with systems such as a powertrain, wheels, brake & steering system, carrier frame & suspension system, and outrigger mechanisms. Main system electric & safety equipment with systems such as lamps & dashboards, and safety devices. The main system of the upper structure system consists of a swing mechanism, boom mechanism, and lifting device. Of course, the failure of the mobile crane system and function will cause substantial losses to operational activities both onshore and offshore. Proper maintenance is required for material/logistics loading and unloading operations at the Jetty with mobile cranes that are operated continuously to run smoothly. The company currently implements a mobile crane maintenance strategy using preventive and corrective maintenance methods.
Other obstract
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| Item Type: | Thesis (Doktor) |
|---|---|
| Identification Number: | 0623070002 |
| Uncontrolled Keywords: | machine effectiveness, machine reliability, maintenance performance level, mobile crane, overall equipment effectiveness, optimization |
| Subjects: | 600 Technology (Applied sciences) > 621 Applied physics > 621.8 Machine engineering |
| Divisions: | S2/S3 > Doktor Teknik Mesin, Fakultas Teknik |
| Depositing User: | Endang Susworini |
| Date Deposited: | 25 Jul 2023 02:33 |
| Last Modified: | 25 Jul 2023 02:33 |
| URI: | http://repository.ub.ac.id/id/eprint/202095 |
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